Integrated optics beam deflectors

ABSTRACT

This invention discloses an optical device including at least one first substrate defining a multiplicity of optical fiber positioning grooves, a multiplicity of optical fibers fixed in each of said multiplicity of optical fiber positioning grooves on the at least one first substrate, whereby the multiplicity of optical fibers lie in an optical fiber plane and the ends of each of the multiplicity of optical fibers lie substantially in a first predetermined arrangement in the optical fiber plane, a second substrate fixed onto the at least one first substrate such that an edge of the second substrate extends beyond the ends of each of the multiplicity of optical fibers, a lens assembly including a third substrate, and a lens fixed onto the third substrate, the lens assembly being mounted onto the second substrate such that the lens lies in a second predetermined arrangement with respect to the ends of each of the multiplicity of optical fibers, whereby the separation between the lens and the ends of each of the multiplicity of optical fibers is defined in a plane perpendicular to the optical fiber plane to a first degree of accuracy and the separation between the lens and the ends of each of the multiplicity of optical fibers is defined in the optical fiber plane to a second degree of accuracy, less than the first degree of accuracy.  
     A method for producing an optical device including at least one first substrate defining a multiplicity of optical fiber positioning grooves is also disclosed.

FIELD OF THE INVENTION

[0001] The present invention relates to integrated optical devicesgenerally and more particularly to packaging of integrated opticaldevices.

BACKGROUND OF THE INVENTION

[0002] Various types of integrated optical devices are known. It is wellknown to pigtail an optical fiber onto an integrated optical device.Difficulties arise, however, when it is sought to pigtail multipleoptical fibers onto integrated optical devices. When the optical modesin waveguides and optical fibers are similar, it is conventional topigtail them by suitable alignment and butt coupling in an integratedoptical device.

[0003] When there exists a substantial disparity in the respectiveoptical modes of the optical fibers and the waveguides, optical elementsmust be employed to enable successful pigtailing. Particularly when theoptical modes are relatively small, very high alignment accuracy isrequired in the alignment of three elements, the waveguide, the opticalelement and the fiber.

[0004] The following patents are believed to representative of thepresent state of the art: 5,737,138; 5,732,181; 5,732,173; 5,721,797;5,712,940; 5,712,937; 5,703,973; 5,703,980; 5,708,741; 5,706,378;5,611,014; 5,600,745; 5,600,741; 5,579,424; 5,570,442; 5,559,915;5,907,649; 5,898,806; 5,892,857; 5,881,190; 5,875,274; 5,867,619;5,859,945; 5,854,868; 5,854,867; 5,828,800; 5,793,914; 5,784,509;5,835,659; 5,656,120; 5,482,585; 5,482,585; 5,625,726; 5,210,800; and5,195,154.

SUMMARY OF THE INVENTION

[0005] The present invention seeks to provide a cost-effective andreliable integrated optics packaging technique and optical devicesconstructed thereby.

[0006] There is thus provided in accordance with a preferred embodimentof the present invention an optical device including at least one firstsubstrate defining a multiplicity of optical fiber positioning grooves,a multiplicity of optical fibers fixed in each of the multiplicity ofoptical fiber positioning grooves on the at least one first substrate,whereby the multiplicity of optical fibers lie in an optical fiber planeand the ends of each of the multiplicity of optical fibers liesubstantially in a first predetermined arrangement in the optical fiberplane, a second substrate fixed onto the at least one first substratesuch that an edge of the second substrate extends beyond the ends ofeach of the multiplicity of optical fibers, a lens assembly including athird substrate, and a lens fixed onto the third substrate, the lensassembly being mounted onto the second substrate such that the lens liesin a second predetermined arrangement with respect to the ends of eachof the multiplicity of optical fibers, whereby the separation betweenthe lens and the ends of each of the multiplicity of optical fibers isdefined in a plane perpendicular to the optical fiber plane to a firstdegree of accuracy and the separation between the lens and the ends ofeach of the multiplicity of optical fibers is defined in the opticalfiber plane to a second degree of accuracy, less than the first degreeof accuracy.

[0007] Further in accordance with a preferred embodiment of the presentinvention the at least one first substrate comprises a pair of firstsubstrates having the optical fiber positioning grooves thereon arrangedin mutually facing relationship.

[0008] Still further in accordance with a preferred embodiment of thepresent invention the lens comprises a cylindrical lens which extendsalong a cylindrical lens axis. Preferably the cylindrical lens axis liesparallel to the optical fiber plane.

[0009] Additionally in accordance with a preferred embodiment of thepresent invention the third substrate is fixed in engagement with theedge of the second substrate by an adhesive. Preferably the thirdsubstrate is fixed in engagement with the edge of the second substrateby an adhesive.

[0010] Additionally in accordance with a preferred embodiment of thepresent invention the multiplicity of optical fiber positioning groovesare mutually parallel. Preferably the multiplicity of optical fiberpositioning grooves are arranged in a fan arrangement in order tocompensate for optical aberrations.

[0011] There is also provided in accordance with a preferred embodimentof the present invention a method for producing an optical deviceincluding the steps of forming a multiplicity of optical fiberpositioning grooves on at least one first substrate, placing each of amultiplicity of optical fibers in each of the multiplicity of opticalfiber positioning grooves on the at least one first substrate, retainingeach of the multiplicity of optical fibers in each of the multiplicityof optical fiber positioning grooves on the at least one firstsubstrate, such that the multiplicity of optical fibers lie in anoptical fiber plane, precisely defining the ends of each of themultiplicity of optical fibers so that they all lie substantially in afirst predetermined arrangement, fixing a second substrate onto the atleast one first substrate such that an edge of the second substrateextends beyond the ends of each of the multiplicity of optical fibers,fixing a lens onto a third substrate, precisely aligning the thirdsubstrate in engagement with the edge of the second substrate such thatthe lens lies in a second predetermined arrangement with respect to theends of each of the multiplicity of optical fibers, and fixing the thirdsubstrate in engagement with said edge of the second substrate such thatthe lens lies in a second predetermined arrangement with respect to theends of each of the multiplicity of optical fibers, whereby theseparation between the lens and the ends of each of the multiplicity ofoptical fibers is defined in a plane perpendicular to the optical fiberplane to a first degree of accuracy and the separation between the lensand the ends of each of the multiplicity of optical fibers is defined inthe optical fiber plane to a second degree of accuracy, less than thefirst degree of accuracy. Preferably the step of fixing the thirdsubstrate in engagement with the edge employs an adhesive and the stepof precisely aligning the third substrate in engagement with the edge ofthe second substrate employs an external positioner.

[0012] Further in accordance with a preferred embodiment of the presentinvention the at least one first substrate includes a pair of firstsubstrates having the optical fiber positioning grooves thereon arrangedin mutually facing relationship.

[0013] Additionally or alternatively the lens includes a cylindricallens which extends along a cylindrical lens axis. Preferably theprecisely aligning step and the fixing step arrange the cylindrical lenssuch that the cylindrical lens axis lies parallel to the optical fiberplane.

[0014] Preferably the multiplicity of optical fiber positioning groovesare mutually parallel.

[0015] Alternatively accordance with a preferred embodiment of thepresent invention the multiplicity of optical fiber positioning groovesare arranged in a fan arrangement in order to compensate for opticalaberrations.

[0016] There is further provided in accordance with a preferredembodiment of the present invention an optical device including at leastone optical substrate having formed thereon at least one waveguide, atleast one base substrate onto which the at least one optical substrateis fixed, and at least one optical module, precisely positioned ontoeach at least one base substrate and fixed thereto by means of sidemounting blocks thereby to preserve precise mutual alignment of the atleast one module and the at least one waveguide.

[0017] Further in accordance with a preferred embodiment of the presentinvention the at least one optical module includes a lens or includes acylindrical lens, and at least one optical fiber.

[0018] Preferably the at least one optical module also includes a lenswhich is operative to couple light from the at least one fiber to the atleast one waveguide and also including the step of positioning outputoptics including at least one output fiber on the at least one basesubstrate so as to receive light from the at least one waveguide.Additionally or alternatively the lens is operative to couple light froma first number of fibers to a greater number of waveguides.

[0019] Additionally in accordance with a preferred embodiment of thepresent invention the at least one waveguide includes stacking aplurality of base substrates each having mounted thereon at least oneoptical substrate having formed thereon at least one waveguide andwherein the step of positioning the output optics includes arranging atleast one lens to receive light from waveguides formed on multiple onesof the plurality of optical substrates. Preferably the step ofpositioning the output optics includes employing side mounting blocksthereby to- preserve precise mutual alignment of said at least one lensand the at least one waveguide.

[0020] Still further in accordance with a preferred embodiment of thepresent invention the step of positioning output optics includesemploying side mounting blocks thereby to preserve precise mutualalignment of said at least one lens and said at least one waveguide, andthe at least one waveguide includes a multiplicity of waveguides. Thestep of positioning the output optics includes positioning at least onelens so as to receive light from multiple ones of the multiplicity ofwaveguides.

[0021] Still further in accordance with a preferred embodiment of thepresent invention the lens is operative to couple light from a firstnumber of fibers to an identical number of waveguides. Preferably thefirst number of waveguides comprises at least one waveguide.

[0022] Still further in accordance with a preferred embodiment of thepresent invention the at least one optical substrate is a lightdeflector.

[0023] Additionally in accordance with a preferred embodiment of thepresent invention, the optical device includes output optics receivinglight from the at least one waveguide and including at least one outputfiber.

[0024] Additionally or alternatively the output optics includes at leastone lens fixed onto the base substrate by means of side mounting blocksthereby to preserve precise mutual alignment of the at least one lensand the at least one waveguide. The at least one optical substrate maybe a light deflector and preferably the at least one optical substrateis formed of gallium arsenide.

[0025] Still further in accordance with a preferred embodiment of thepresent invention the at least one waveguide includes a multiplicity ofwaveguides and wherein the output optics includes at least one lensreceiving light from multiple ones of the multiplicity of waveguides.Additionally or alternatively the output optics includes at least onelens receiving light from waveguides formed on multiple ones of theplurality of optical substrates. Furthermore the at least one opticalsubstrate may be a light deflector.

[0026] The output optics may also include at least one lens fixed ontothe base substrate by means of side mounting blocks thereby to preserveprecise mutual alignment of the at least one lens and the at least onewaveguide.

[0027] Additionally or preferably the at least one optical substrate isformed of gallium arsenide.

[0028] Still further in accordance with a preferred embodiment of thepresent invention the optical module includes at least one firstsubstrate defining a multiplicity of optical fiber positioning grooves,a multiplicity of optical fibers fixed in each of the multiplicity ofoptical fiber positioning grooves on the at least one first substrate,whereby the multiplicity of optical fibers lie in an optical fiberplane. The ends of each of the multiplicity of optical fibers may liesubstantially in a first predetermined arrangement in the optical fiberplane. A second substrate is preferably fixed on at least one firstsubstrate such that an edge of the second substrate extends beyond theends of each of the multiplicity of optical fibers, a lens assemblyincluding a third substrate, and a lens fixed onto the third substrate,the lens assembly being mounted onto the second substrate such that thelens lies in a second predetermined arrangement with respect to the endsof each of the multiplicity of optical fibers. The separation betweenthe lens and the ends of each of the multiplicity of optical fibers maybe defined in a plane perpendicular to the optical fiber plane to afirst degree of accuracy and the separation between the lens and theends of each of the multiplicity of optical fibers may be defined in theoptical fiber plane to a second degree of accuracy, less than the firstdegree of accuracy.

[0029] Further in accordance with a preferred embodiment of the presentinvention the lens includes a cylindrical lens.

[0030] Additionally in accordance with a preferred embodiment of thepresent invention also including output optics receiving light from theat least one waveguide and including at least one output fiber.Additionally or alternatively the output optics includes at least onelens fixed onto the base substrate by means of side mounting blocksthereby to preserve precise mutual alignment of the at least one lensand the at least one waveguide. Preferably the at least one opticalsubstrate is a light deflector and the at least one optical substrate isformed of gallium arsenide.

[0031] Further in accordance with a preferred embodiment of the presentinvention the at least one waveguide includes a multiplicity ofwaveguides and wherein the output optics includes at least one lensreceiving light from multiple ones of the multiplicity of waveguides.Additionally or alternatively the multiplicity of waveguides is formedon a plurality of optical substrates and the output optics includes atleast one lens receiving light from waveguides formed on multiple onesof the plurality of optical substrates.

[0032] Preferably the at least one optical substrate is a lightdeflector and the output optics includes at least one lens fixed ontothe base substrate by means of side mounting blocks thereby to preserveprecise mutual alignment of the at least one lens and the at least onewaveguide. The at least one optical substrate may be formed of galliumarsenide.

[0033] There is also provided in accordance with a preferred embodimentof the present invention an optical device including at least oneoptical substrate having formed thereon at least one waveguide having acenter which lies in a waveguide plane, a base substrate onto which theat least one optical substrate is fixed and defining at least oneoptical fiber positioning groove, and at least one optical fiber fixedin the at least one optical fiber positioning groove on the basesubstrate, whereby a center of the at least one optical fiber lies in aplane which is substantially coplanar with the waveguide plane.

[0034] Preferably electrical connections are mounted on the basesubstrate.

[0035] Additionally the at least one optical module is preciselypositioned onto the base substrate and fixed thereto by means of sidemounting blocks thereby to preserve precise mutual alignment of the atleast one module and the at least one waveguide.

[0036] Additionally or alternatively the at least one optical substrateis a light deflector.

[0037] There is further provided in accordance with a preferredembodiment of the present invention a method for producing an opticaldevice including the steps of forming at least one waveguide onto atleast one optical substrate, mounting the at least one optical substrateonto at least one base substrate, and precisely positioning at least oneoptical module onto the base substrate, including employing sidemounting blocks thereby to preserve precise mutual alignment of the atleast one module and the at least one waveguide.

[0038] Additionally or alternatively the at least one optical modulecomprises a lens which is preferably a cylindrical lens.

[0039] Further in accordance with a preferred embodiment of the presentinvention the at least one optical module includes at least one opticalfiber. Additionally or alternatively the at least one optical modulealso includes a lens which is operative to couple light from the atleast one fiber to the at least one waveguide. Preferably the lens isoperative to couple light from a first number of fibers to a greaternumber of waveguides.

[0040] Alternatively the lens is operative to couple light from a firstnumber of fibers to an identical number of waveguides.

[0041] Additionally in accordance with a preferred embodiment of thepresent invention the first number of waveguides includes at least onewaveguide.

[0042] Still further in accordance with a preferred the at least oneoptical substrate is a light deflector.

[0043] Additionally in accordance with a preferred embodiment of thepresent invention, the method for producing an optical device alsoincludes the steps of providing output optics receiving light from theat least one waveguide and including at least one output fiber.Furthermore, the output optics may include at least one lens fixed ontothe base substrate by means of side mounting blocks thereby to preserveprecise mutual alignment of the at least one lens and the at least onewaveguide. Additionally or alternatively the at least one opticalsubstrate is a light deflector. Preferably the at least one opticalsubstrate is formed of gallium arsenide.

[0044] Still further in accordance with a preferred embodiment of thepresent invention the at least one waveguide includes a multiplicity ofwaveguides and wherein the output optics includes at least one lensreceiving light from multiple ones of the multiplicity of waveguides.

[0045] Further in accordance with a preferred embodiment of the presentinvention the at least one waveguide includes a multiplicity ofwaveguides formed on a plurality of optical substrates and wherein theoutput optics includes at least one lens receiving light from waveguidesformed on multiple ones of the plurality of optical substrates.Additionally or alternatively the at least one optical substrate is alight deflector. Preferably the output optics includes at least one lensfixed onto the base substrate by means of side mounting blocks therebyto preserve precise mutual alignment of the at least one lens and the atleast one waveguide. Preferably the at least one optical substrate isformed of gallium arsenide.

[0046] Still further in accordance with a preferred embodiment of thepresent invention the optical module includes at least one firstsubstrate defining a multiplicity of optical fiber positioning grooves,a multiplicity of optical fibers fixed in each of the multiplicity ofoptical fiber positioning grooves on the at least one first substrate,whereby the multiplicity of optical fibers lie in an optical fiber planeand the ends of each of the multiplicity of optical fibers liesubstantially in a first predetermined arrangement in the optical fiberplane, a second substrate fixed onto the at least one first substratesuch that an edge of the second substrate extends beyond the ends ofeach of the multiplicity of optical fibers, a lens assembly including athird substrate, and a lens fixed onto the third substrate, the lensassembly being mounted onto the second substrate such that the lens liesin a second predetermined arrangement with respect to the ends of eachof the multiplicity of optical fibers, whereby the separation betweenthe lens and the ends of each of the multiplicity of optical fibers isdefined in a plane perpendicular to the optical fiber plane to a firstdegree of accuracy and the separation between the lens and the ends ofeach of the multiplicity of optical fibers is defined in the opticalfiber plane to a second degree of accuracy, less than the first degreeof accuracy.

[0047] Additionally or alternatively the lens includes a cylindricallens. Preferably the at least one optical substrate is a lightdeflector.

[0048] Additionally in accordance with a preferred embodiment of thepresent invention and also including providing output optics receivinglight from said at least one waveguide and including at least one outputfiber. Additionally or alternatively the output optics includes at leastone lens fixed onto the base substrate by means of side mounting blocksthereby to preserve precise mutual alignment of the at least one lensand the at least one waveguide. The at least one optical substrate maybe a light deflector and preferably the at least one optical substrateis formed of gallium arsenide.

[0049] Still further according to a preferred embodiment of the presentinvention the at least one waveguide includes a multiplicity ofwaveguides and wherein the output optics includes at least one lensreceiving light from multiple ones of the multiplicity of waveguides.

[0050] Further in accordance with a preferred embodiment of the presentinvention the at least one waveguide includes a multiplicity ofwaveguides formed on a plurality of optical substrates and wherein theoutput optics includes at least one lens receiving light from waveguidesformed on multiple ones of the plurality of optical substrates.Preferably the at least one optical substrate is a light deflector.

[0051] Additionally in accordance with a preferred embodiment of thepresent invention the output optics includes at least one lens fixedonto the base substrate by means of side mounting blocks thereby topreserve precise mutual alignment of the at least one lens and the atleast one waveguide. Preferably the at least one optical substrate isformed of gallium arsenide.

[0052] There is also provided in accordance with yet another preferredembodiment of the present invention a method including forming on atleast one optical substrate at least one waveguide having a center whichlies in a waveguide plane, fixing the at least one optical substrateonto a base substrate and defining on the base substrate at least oneoptical fiber positioning groove, and fixing at least one optical fiberin the at least one optical fiber positioning groove on the basesubstrate, whereby a center of the at least one optical fiber lies in aplane which is substantially coplanar with the waveguide plane.

[0053] Preferably electrical connections are mounted on the basesubstrate.

[0054] Additionally the at least one optical module is preciselypositioned onto the base substrate and fixed thereto by means of sidemounting blocks thereby to preserve precise mutual alignment of the atleast one module and the at least one waveguide.

[0055] Still further in accordance with a preferred embodiment of thepresent invention the at least one optical substrate is a lightdeflector. Preferably also including mounting electrical connections onsaid base substrate.

[0056] There is further provided in accordance with another preferredembodiment of the present invention a method for producing an opticaldevice including the steps of lithographically forming a multiplicity ofwaveguides onto an optical substrate, mounting the optical substrateonto a base substrate, and precisely positioning a fiber optic module,having a multiplicity of optical fiber ends and an optical modemodifying lens, onto the base substrate, including using at least oneexternal positioner, manipulating at least one of the fiber optic moduleand the base substrate relative to the other such that the mode of eachoptical fiber matches the mode of at least one corresponding waveguidewith relatively low light loss, and fixing the fiber optic module in adesired relative position on the base substrate independently of theexternal positioner, and disengaging the at least one externalpositioner from the modulated light source.

[0057] Further in accordance with a preferred embodiment of the presentinvention the step of fixing includes employing side mounting blocks tofix the module in position on the base substrate upon precise mutualalignment of the module and the multiplicity of waveguides.

[0058] Still further in accordance with a preferred embodiment of thepresent invention also including the step of producing a fiber opticmodule which includes the steps of forming a multiplicity of opticalfiber positioning grooves on at least one first substrate, placing eachof a multiplicity of optical fibers in each of the multiplicity ofoptical fiber positioning grooves on the at least one first substrate,retaining each of the multiplicity of optical fibers in each of themultiplicity of optical fiber positioning grooves on the at least onefirst substrate, such that the multiplicity of optical fibers lie in anoptical fiber plane, precisely defining the ends of each of themultiplicity of optical fibers so that they all lie substantially in afirst predetermined arrangement, fixing a second substrate onto thefirst substrate such that an edge of the second substrate extends beyondthe ends of each of the multiplicity of optical fibers, fixing a lensonto a third substrate, precisely aligning the third substrate inengagement with the edge of the second substrate such that the lens liesin a second predetermined arrangement with respect to the ends of eachof the multiplicity of optical fibers, and fixing the third substrate inengagement with the edge of the second substrate such that the lens liesin a second predetermined arrangement with respect to the ends of eachof the multiplicity of optical fibers, whereby the separation betweenthe lens and the ends of each of the multiplicity of optical fibers isdefined in a plane perpendicular to the optical fiber plane to a firstdegree of accuracy and the separation between the lens and the ends ofeach of the multiplicity of optical fibers is defined in the opticalfiber plane to a second degree of accuracy, less than the first degreeof accuracy.

[0059] Preferably the optical substrate is gallium arsenide and theoptical device functions as a switch.

BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The present invention will be understood and appreciated morefully from the following detailed description, taken in conjunction withthe drawings in which:

[0061] FIGS. 1A-1I are simplified pictorial illustrations of a methodfor producing an optical fiber module in accordance with a preferredembodiment of the present invention;

[0062]FIG. 2A-2C are simplified pictorial illustrations of threealternative embodiments of a method for mounting an active integratedoptics waveguide assembly onto a base substrate which are useful in thepresent invention;

[0063] FIGS. 3A-3F are simplified pictorial illustrations of a methodfor producing an optical device using an optical fiber module and anintegrated optics waveguide assembly in accordance with a preferredembodiment of the present invention corresponding to FIGS. 2A and 2B;

[0064] FIGS. 4A-4F are simplified pictorial illustrations of a methodfor producing an optical device using an optical fiber module and anintegrated optics waveguide assembly in accordance with anotherpreferred embodiment of the present invention corresponding to theembodiment of FIG. 2C;

[0065] FIGS. 5A-5F are simplified pictorial illustrations of a methodfor producing an optical device using an optical fiber module and anintegrated optics waveguide assembly in accordance with yet anotherpreferred embodiment of the present invention corresponding to theembodiment of FIG. 2C;

[0066] FIGS. 6A-6E are simplified pictorial illustrations of a methodfor associating output optics with the optical device of FIG. 3F inaccordance with a preferred embodiment of the present invention;

[0067] FIGS. 7A-7D are simplified pictorial illustrations of a methodfor constructing an integrated optics optical fiber switch using aplurality of base substrates bearing integrated optics waveguideassemblies and optical fiber modules as shown in FIG. 3F;

[0068] FIGS. 8A-8D are simplified pictorial illustrations of a methodfor associating output optics with the optical device of FIG. 4F inaccordance with a preferred embodiment of the present invention;

[0069] FIGS. 9A-9D are simplified pictorial illustrations of a methodfor constructing an integrated optics optical fiber switch using aplurality of base substrates bearing integrated optics waveguideassemblies and optical fiber modules as shown in FIG. 4F.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0070] Reference is now made to FIGS. 1A-1I, which are simplifiedpictorial illustrations of a method for producing an optical fibermodule in accordance with a preferred embodiment of the presentinvention. The method preferably begins with the provision of aV-grooved substrate, such as substrate 10 in FIG. 1A or substrate 12 inFIG. 1B. The substrate is typically silicon, but may alternatively besilica, glass or any other suitable material.

[0071] The V-grooves may be parallel as shown in FIG. 1A at referencenumeral 14 or non-parallel as shown in FIG. 1B at reference numeral 16.The description that follows refers to a parallel orientation, it beingunderstood that a non-parallel orientation may be employed instead.

[0072] Preferably, the V-grooves are formed by lithography or bygrinding. The accuracy of the dimensions of the V-grooves is preferablyto a fraction of a micron, such that when optical fibers 20 are securedin the V-grooves 22 formed in a substrate 24, as shown in FIG. 1C, theirrelative alignment is within one-half micron in two dimensions.

[0073] Following placement of the optical fibers 20 in V-grooves 22, asshown in FIG. 1C, the fibers are secured in position by a cover element26, as shown in Fig. 1D. The cover element 26 may be identical to theV-grooved substrate 24 in an upside down orientation.

[0074] It is appreciated that the ends of the optical fibers 20 may allbe suitably aligned at the time of their placement in the V-grooves.Preferably, however, this alignment is not required and followingplacement of the fibers and securing thereof in the V-grooves 22, thefiber ends are cut and polished together with substrate 24 and coverelement 26 such that the fiber ends lie in the same plane as the edge ofthe substrate 24 and cover 26. In Fig. 1D, this plane is indicated byreference numeral 28.

[0075] Preferably, suitable adhesive is employed both at the stagesshown in FIGS. 1C and 1D to retain the fibers in place and subsequentlyto hold the cover element 26 onto substrate 24 in secure engagement withfibers 20.

[0076] As seen in FIG. 1E, a sheet of glass 30 or any other suitablesubstrate, which is preferably transparent for ease of alignment, isaligned with cover element 26 such that at least one edge 32 thereoflies in highly accurate parallel alignment with plane 28, and separatelytherefrom by a precisely determined distance. The substrate 30 is thenfixed onto cover element 26, as by means of a UV curable adhesive 27 anda UV light source 29, as shown in FIG. 1F.

[0077] Referring now to FIG. 1G, a lens 40, preferably a cylindricallens, which is mounted onto a mounting substrate 42, is aligned withrespect to edge 32 of substrate 30. This alignment is preferablyprovided to a high degree of accuracy, to the order of one-half micron,by means of a vacuum engagement assembly 44 connected to a suitablepositioner, not shown, such as Melees Grist Nanoblock. This degree ofaccuracy is greater than that required in the parallelism and separationdistance between edge 32 and plane 28. As seen in FIG. 1H, the substrate42 is then fixed onto edge 32 of substrate 30, as by means of a UVcurable adhesive 41 and the UV light source 29.

[0078]FIG. 1I illustrates the resulting optical relationship between theoptical modes 50 of the fibers 20, which are seen to be circularupstream of lens 40 and the optical modes 52 downstream of the lens 40,which are seen to be highly elliptical. It is appreciated that it is aparticular advantage of the present invention that the highly ellipticalmodes which are produced by lens 40 are very similar to whose inintegrated optical waveguides, as is described in applicant's publishedPCT application WO 98/59276. Furthermore, the arrangement describedhereinabove produces a mode from a single fiber which is sufficientlyhighly elliptical so that it may be coupled to a multiplicity ofwaveguides arranged side by side, as described in applicant's publishedPCT application WO 98/59276, the contents of which are herebyincorporated by reference. It is appreciated that in accordance with apreferred embodiment of the present invention, lens 40 may couple asingle fiber to a single waveguide or to multiple waveguides.

[0079] Reference is now made to FIG. 2A-2C, which are simplifiedpictorial illustrations of three alternative embodiments of a method formounting an active integrated optics waveguide assembly onto a basesubstrate which is useful in the present invention.

[0080]FIG. 2A illustrates flip-chip type mounting of an integratedoptics waveguide device 100, such as a waveguide device described andclaimed in applicant's published PCT application WO 98/59276, thedisclosure of which is hereby incorporated by reference. Device 100 ispreferably embodied in a flipchip package, such as that described inFIG. 31 of applicants published PCT application WO 98/59276. In thisembodiment, device 100 is mounted onto an integrated electronic circuit102, such as an ASIC.

[0081]FIG. 2B illustrates conventional wire bond type mounting of anintegrated optics waveguide device 104, such as a waveguide devicedescribed and claimed in applicant's published PCT application WO98/59276, the disclosure of which is hereby incorporated by reference.Device 104 is preferably embodied in a wire bond package, such as thatdescribed in FIG. 30 of applicant's published PCT application WO98/59276.

[0082]FIG. 2C illustrates conventional flip-chip type mounting of anintegrated optics waveguide device 100, such as a waveguide devicedescribed and claimed in applicant's published PCT application WO98/59276, the disclosure of which is hereby incorporated by reference.Device 100 is preferably embodied in a flip-chip package, such as thatdescribed in FIG. 31 of applicant's published PCT application WO98/59276.

[0083] The mountings of FIGS. 2A and 2B are both characterized in thatthe waveguides of the active integrated optics waveguide device arelocated in a plane which is spaced from the surface of a substrate by adistance of at least a few hundred microns. This may be contrasted fromthe mounting of FIG. 2C, wherein the waveguides of the active integratedoptics waveguide device are located in a plane which is spaced from thesurface of a substrate by a distance of less than one hundred microns.

[0084] Reference is now made to FIGS. 3A-3F, which are simplifiedpictorial illustrations of a method for producing an optical deviceusing an optical fiber module and an integrated optics waveguideassembly in accordance with a preferred embodiment of the presentinvention. The illustrations of FIGS. 3A-3F show a mounting of the typeillustrated in FIGS. 2A & 2B.

[0085]FIG. 3A shows a substrate 200 onto which is mounted an activeintegrated optics waveguide device 202 as well as various otherintegrated circuits 204. As seen in FIG. 3B, an optical fiber module206, preferably of the type described hereinabove with reference toFIGS. 1A-1I, is brought into proximity with substrate 200 and activeintegrated optics waveguide device 202, as by a vacuum engagementassembly 208, connected to a suitable positioner (not shown), such asMelles Griot Nanoblock.

[0086] As seen in FIG. 3C, the optical fiber module 206 is preciselypositioned with respect to the active integrated optics waveguide device202 with six degrees of freedom so as to achieve a high degree ofaccuracy in order to realize optimal optical coupling efficiency betweenthe fibers in module 206 and the waveguides in device 202. This degreeof accuracy is greater than that required in the previously describedalignment steps illustrated in FIGS. 1A-1I and preferably reaches onetenth of a micron.

[0087]FIG. 3D illustrates precise mounting of the optical fiber module206 with respect to the active integrated optics waveguide device 202 onsubstrate 200. This precise mounting is preferably achieved by using thepositioner (not shown) to manipulate the fiber optic module 206 relativeto substrate 200 such that the mode of each optical fiber 209 in module206 matches the mode of at least one corresponding waveguide ofwaveguide device 202 with relatively low light loss.

[0088] The fiber optic module 206 is mounted in a desired relativeposition on the substrate 200 independently of the positioner byemploying side mounting blocks 210 to fix the module 206 in position onsubstrate 200 upon precise mutual alignment of the module 206 and thewaveguide device 202.

[0089] Preferably side mounting blocks 210 are carefully positionedalongside module 206 and are bonded thereto and to substrate 200,preferably using a thin layer of UV curable adhesive 211 which does notinvolve significant shrinkage during curing, as by use of a UV lightsource 220 as shown in FIG. 3E, so that the relative position shown inFIG. 3D is preserved, as seen in FIG. 3F. It is appreciated that inorder to affix the mounting blocks 210 to the substrate 200, a coatingof the adhesive 211 is applied to the appropriate side surfaces andlower surfaces of the mounting blocks 210.

[0090] The use of side mounting blocks 210 enables accurate fixationwith six degrees of freedom by virtue of the use of the thin layer ofadhesive 211, which does not involve significant shrinkage duringcuring, along two mutually orthogonal planes.

[0091] Reference is now made to FIGS. 4A-4F, which are simplifiedpictorial illustrations of a method for producing an optical deviceusing an optical fiber module and an integrated optics waveguideassembly in accordance with another preferred embodiment of the presentinvention corresponding to the embodiment of FIG. 2C.

[0092] As noted above, in the mounting arrangement of FIG. 2C, thewaveguides of the active integrated optics waveguide device are locatedin a plane which is spaced from the surface of a substrate by a distanceof less than one hundred microns. In order to accommodate this verysmall spacing a hole or a recess is formed in the substrate to receivethe optical fiber module. FIG. 4A shows a substrate 300 onto which ismounted an active integrated optics waveguide device 302 as well asvarious other integrated circuits 304. A hole or recess 305 ispreferably formed in substrate 300 as shown. As seen in FIG. 4B, anoptical fiber module 306, preferably of the type described hereinabovewith reference to FIGS. 1A-1I, is brought into proximity with substrate300 and active integrated optics waveguide device 302, as by a vacuumengagement assembly 308, connected to a suitable positioner (not shown),such as Melles Griot Nanoblock.

[0093] As seen in FIG. 4C, the optical fiber module 306 is preciselypositioned with respect to the active integrated optics waveguide device302 with six degrees of freedom so as to achieve a high degree ofaccuracy in order to realize optimal optical coupling efficiency betweenthe fibers in module 306 and the waveguides in device 302. This degreeof accuracy is greater than that required in the previously describedalignment steps illustrated in FIGS. 1A-1I and preferably reaches onetenth of a micron.

[0094]FIG. 4D illustrates precise mounting of the optical fiber module306 with respect to the active integrated optics waveguide device 302 onsubstrate 300 partially overlapping hole 305, such that the cylindricallens, such as lens 40 (FIG. 1H) and the ends of the optical fibers, suchas fibers 20 (Fig. 1D) lie partially below the top surface of substrate300. This construction ensures that the images of the centers of theends of fibers 20 lie in the same plane as the centers of the waveguidesof waveguide device 302. This precise mounting is preferably achieved byusing the positioner (not shown) to manipulate the fiber optic module306 relative to substrate 300 such that the mode of each optical fiber20 in module 306 matches the mode of at least one correspondingwaveguide of waveguide device 302 with relatively low light loss.

[0095] The fiber optic module 306 is mounted in a desired relativeposition on the substrate 302 independently of the positioner byemploying side mounting blocks 310 to fix the module 306 in position onsubstrate 300 upon precise mutual alignment of the module 306 and thewaveguide device 302.

[0096] Preferably side mounting blocks 310 are carefully positionedalongside module 306 and are bonded thereto and to substrate 300,preferably using a thin layer of UV curable adhesive 311 which does notinvolve significant shrinkage during curing, as by use of a UV lightsource 320 as shown in FIG. 4E, so that the relative position shown inFIG. 4D is preserved, as seen in FIG. 4F.

[0097] The use of side mounting blocks 310 enables accurate fixationwith six degrees of freedom by virtue of the use of the thin layer ofadhesive 311, which does not involve significant shrinkage duringcuring, along two mutually orthogonal planes.

[0098] Reference is now made to FIGS. 5A-5F, which are simplifiedpictorial illustrations yet another method for producing an opticaldevice using an optical fiber module and an integrated optics waveguideassembly in accordance with yet another preferred embodiment of thepresent invention corresponding to the embodiment of FIG. 2C.

[0099]FIG. 5A shows a substrate 400 onto which is mounted an activeintegrated optics waveguide device 402 as well as various otherintegrated circuits 404. A hole or recess 405 is preferably formed insubstrate 400 as shown.

[0100] In this embodiment a multiplicity of optical fibers 406 aremounted in V-grooves 407 formed in substrate 400, such that the centersof the ends of fibers 406 all lie in the same plane as that of thecenters of the waveguides of waveguide device 402. It is appreciatedthat this type of structure may be adapted for use with the embodimentof FIGS. 2A and 2B by providing a raised platform portion of substrate400 underlying V-grooves 407. In such an arrangement, the centers of theends of fibers 406 would all lie in the same plane as that of thecenters of the waveguides of waveguide device 100 (FIG. 2A) or 104 (FIG.2B).

[0101] As seen in FIG. 5B, a lens module 408, preferably comprising alens 409 fixedly mounted onto a mounting substrate 410, is brought intoproximity with substrate 400 and active integrated optics waveguidedevice 402, as by a vacuum engagement assembly 411, connected to asuitable positioner (not shown), such as Melles Griot Nanoblock.

[0102] As seen in FIG. 5C, the lens module 408 is precisely positionedwith respect to the active integrated optics waveguide device 402 withsix degrees of freedom so as to achieve a high degree of accuracy inorder to realize optimal optical coupling efficiency between the fibers406 and the waveguides in device 402. This degree of accuracy is greaterthan that required in the previously described alignment stepsillustrated in FIGS. 1A-1I and preferably reaches one tenth of a micron.

[0103]FIG. 5D illustrates precise mounting of the lens module 408 withrespect to the active integrated optics waveguide device 402 onsubstrate 400 partially overlapping hole 405, such that the lens 409lies partially below the top surface of substrate 400. This constructionensures that the images of the centers of the ends of fibers 406 lie inthe same plane as the centers of the waveguides of waveguide device 402.This precise mounting is preferably achieved by using the positioner(not shown) to manipulate the lens module 408 relative to substrate 400such that the mode of each optical fiber 406 matches the mode of atleast one corresponding waveguide of waveguide device 402 withrelatively low light loss.

[0104] The lens module 408 is mounted in a desired relative position onthe substrate 400 independently of the positioner by employing sidemounting blocks 412 to fix the module 408 in position on substrate 400upon precise mutual alignment of the module 408 and the waveguide device402.

[0105] Preferably side mounting blocks 412 are carefully positionedalongside module 408 and are bonded thereto and to substrate 400,preferably using a thin layer of UV curable adhesive 413 which does notinvolve significant shrinkage during curing, as by use of a UV lightsource 420 as shown in FIG. 5E, so that the relative position shown inFIG. 5D is preserved, as seen in FIG. 5F.

[0106] The use of side mounting blocks 412 enables accurate fixationwith six degrees of freedom by virtue of the use of the thin layer ofadhesive 413, which does not involve significant shrinkage duringcuring, along two mutually orthogonal planes.

[0107] Reference is now made to FIGS. 6A-6E, which are simplifiedpictorial illustrations of a method for associating output optics withthe optical device of FIG. 3F in accordance with a preferred embodimentof the present invention;

[0108]FIG. 6A shows a chassis 500 onto which is mounted an opticaldevice 501, preferably the optical device described hereinabove andshown in FIG. 3F. For the sake of conciseness and clarity, the referencenumerals appearing in FIG. 3F are employed also in FIG. 6A asappropriate. Also mounted on chassis 500 is an optical fiber bundle 502and a lens 504 arranged such that the center of the lens 504 lies in thesame plane as the centers of the ends of the fibers in fiber bundle 502within conventional mechanical tolerances, such as 10-50 microns.

[0109] As seen in FIG. 6A, a lens module 508, preferably comprising alens 509 fixedly mounted onto a mounting substrate 510, is brought intoproximity with substrate 200 of device 501 and active integrated opticswaveguide device 202 of device 501, as by a vacuum engagement assembly511, connected to a suitable positioner (not shown), such as MellesGriot Nanoblock.

[0110] As seen in FIG. 6B, the lens module 508 is precisely positionedwith respect to the active integrated optics waveguide device 202 withsix degrees of freedom so as to achieve a high degree of accuracy inorder to realize optimal optical coupling efficiency between the fibersof fiber bundle 502 and the waveguides in device 202. This degree ofaccuracy is greater than that required in the previously describedalignment steps illustrated in FIGS. 1A-1I and preferably reaches onetenth of a micron.

[0111]FIG. 6C illustrates precise mounting of the lens module 508 withrespect to the active integrated optics waveguide device 202 of device501. This construction ensures that the images of the centers of theends of fibers of fiber bundle 502 lie in the same plane as the centersof the waveguides of waveguide device 202. This precise mounting ispreferably achieved by using the positioner (not shown) to manipulatethe lens module 508 relative to substrate 200 such that the mode of eachoptical fiber in bundle 502 matches the mode of at least onecorresponding waveguide of waveguide device 202 with relatively lowlight loss.

[0112] The lens module 508 is mounted in a desired relative position onthe substrate 200 independently of the positioner by employing sidemounting blocks 512 to fix the module 508 in position on substrate 200upon precise mutual alignment of the module 508 and the waveguide device202.

[0113] Preferably side mounting blocks 512 are carefully positionedalongside module 508 and are bonded thereto and to substrate 200,preferably using a thin layer of UV curable adhesive 513 which does notinvolve significant shrinkage during curing, as by use of a UV lightsource 520 as shown in FIG. 6D, so that the relative position shown inFIG. 6C is preserved, as seen in FIG. 6E.

[0114] The use of side mounting blocks 512 enables accurate fixationwith six degrees of freedom by virtue of the use of the thin layer ofadhesive 513, which does not involve significant shrinkage duringcuring, along two mutually orthogonal planes.

[0115] Reference is now made to FIGS. 7A-7D, which are simplifiedpictorial illustrations of a method for constructing an integratedoptics optical fiber switch using a plurality of base substrates bearingintegrated optics waveguide assemblies and optical fiber modules asshown in FIG. 3F.

[0116] The switch is constructed on the basis of the apparatus shown inFIG. 6E. For the sake of conciseness and clarity, the reference numeralsappearing in FIG. 6E are also employed, as appropriate in FIGS. 7A - 7D.As seen in FIG. 7A an optical device 601, preferably identical tooptical device 501 (FIG. 6E), as shown in FIG. 3F, is stacked overoptical device 501 and spaced therefrom by mounting spacers 602. For thesake of conciseness and clarity, the reference numerals appearing inFIG. 3F are also employed, as appropriate in FIGS. 7A-7D. Spacers 602may be mounted either on device 501 as shown or alternatively on device601 or on chassis 500.

[0117] The alignment between devices 501 and 601 may be withinconventional mechanical tolerances, such as 10 microns. The mostimportant aspect of the alignment between devices 501 and 601 is theparallelism of the planes of the respective substrates 200 of devices501 and 601 about the axes of the waveguides of respective opticaldevices 202.

[0118] As seen in FIG. 7B, a lens module 608, preferably comprising alens 609 fixedly mounted onto a mounting substrate 610, is brought intoproximity with substrate 200 of device 601 and active integrated opticswaveguide device 202 of device 601, as by a vacuum engagement assembly611, connected to a suitable positioner (not shown), such as MellesGriot Nanoblock.

[0119] As seen in FIG. 7C, the lens module 608 is precisely positionedwith respect to the active integrated optics waveguide device 202 ofdevice 601 with six degrees of freedom so as to achieve a high degree ofaccuracy in order to realize optimal optical coupling efficiency betweenthe fibers of fiber bundle 502 and the waveguides in device 202 ofdevice 601. This degree of accuracy is greater than that required in thepreviously described alignment steps illustrated in FIGS. 1A-1I andpreferably reaches one tenth of a micron.

[0120] Precise mounting of the lens module 608 with respect to theactive integrated optics waveguide device 202 of device 601 as describedhereinabove with respect to device 501 ensures that the images of thecenters of the ends of fibers of fiber bundle 502 lie in the same planeas the centers of the waveguides of waveguide device 202 of device 601.This precise mounting is preferably achieved by using the positioner(not shown) to manipulate the lens module 608 relative to substrate 200of device 601 such that the mode of each optical fiber in bundle 502matches the mode of at least one corresponding waveguide of waveguidedevice 202 of device 601 with relatively low light loss.

[0121] As seen in FIG. 7D, the lens module 608 is mounted in a desiredrelative position on the substrate 200 of device 601 independently ofthe positioner by employing side mounting blocks 612 to fix the module608 in position on substrate 200 of device 601 upon precise mutualalignment of the module 608 and the waveguide device 202 of device 601.

[0122] Preferably side mounting blocks 612 are carefully positionedalongside module 608 and are bonded thereto and to substrate 200 ofdevice 601, preferably using a thin layer of UV curable adhesive 613which does not involve significant shrinkage during curing, as by use ofa UV light source (not shown).

[0123] Reference is now made to FIGS. 8A-8D, which are simplifiedpictorial illustrations of a method for associating output optics withthe optical device of FIG. 4F in accordance with a preferred embodimentof the present invention;

[0124]FIG. 8A shows a chassis 700 onto which is mounted an opticaldevice 701, preferably the optical device described hereinabove andshown in FIG. 4F. For the sake of conciseness and clarity, the referencenumerals appearing in FIG. 4F are employed also in FIG. 8A asappropriate. Also mounted on chassis 700 is an optical fiber bundle 702and a lens 704 arranged such that the center of the lens 704 lies in thesame plane as the centers of the ends of the fibers in fiber bundle 702within conventional mechanical tolerances, such as 10-50 microns.

[0125] As seen in FIG. 8A, a lens module 708, preferably comprising alens 709 fixedly mounted onto a mounting substrate 710, is brought intoproximity with substrate 300 of device 701 and active integrated opticswaveguide device 302 of device 701, as by a vacuum engagement assembly711, connected to a suitable positioner (not shown), such as MellesGriot Nanoblock.

[0126] As seen in FIG. 8B, the lens module 708 is precisely positionedwith respect to the active integrated optics waveguide device 302 withsix degrees of freedom so as to achieve a high degree of accuracy inorder to realize optimal optical coupling efficiency between the fibersof fiber bundle 702 and the waveguides in device 302. This degree ofaccuracy is greater than that required in the previously describedalignment steps illustrated in FIGS. 1A-1I and preferably reaches onetenth of a micron.

[0127]FIG. 8C illustrates precise mounting of the lens module 708 withrespect to the active integrated optics waveguide device 302 of device701. This construction ensures that the images of the centers of theends of fibers of fiber bundle 702 lie in the same plane as the centersof the waveguides of waveguide device 302. This precise mounting ispreferably achieved by using the positioner (not shown) to manipulatethe lens module 708 relative to substrate 300 such that the mode of eachoptical fiber in bundle 702 matches the mode of at least onecorresponding waveguide of waveguide device 302 with relatively lowlight loss.

[0128] The lens module 708 is mounted in a desired relative position onthe substrate 300 independently of the positioner by employing sidemounting blocks 712 to fix the module 708 in position on substrate 300upon precise mutual alignment of the module 708 and the waveguide device302.

[0129] Preferably side mounting blocks 712 are carefully positionedalongside module 708 and are bonded thereto and to substrate 300,preferably using a thin layer of UV curable adhesive 713 which does notinvolve significant shrinkage during curing, as by use of a UV lightsource 720 as shown in FIG. 8C, so that the relative position shown inFIG. 8C is preserved, as seen in FIG. 8D.

[0130] The use of side mounting blocks 712 enables accurate fixationwith six degrees of freedom by virtue of the use of the thin layer ofadhesive 713, which does not involve significant shrinkage duringcuring, along two mutually orthogonal planes.

[0131] Reference is now made to FIGS. 9A-9D, which are simplifiedpictorial illustrations of a method for constructing an integratedoptics optical fiber switch using a plurality of base substrates bearingintegrated optics waveguide assemblies and optical fiber modules asshown in FIG. 4F.

[0132] The switch is constructed on the basis of the apparatus shown inFIG. 8D. For the sake of conciseness and clarity, the reference numeralsappearing in FIG. 8D are also employed, as appropriate in FIGS. 9A-9D.As seen in FIG. 9A an optical device 801, preferably identical tooptical device 701 (FIG. 8D), as shown in FIG. 4F, is stacked overoptical device 701 and spaced therefrom by mounting spacers 802. For thesake of conciseness and clarity, the reference numerals appearing inFIG. 4F are also employed, as appropriate in FIGS. 9A-9D. Spacers 802may be may mounted either on device 701 as shown or alternatively ondevice 801 or on chassis 700.

[0133] The alignment between devices 701 and 801 may be withinconventional mechanical tolerances, such as 10 microns. The mostimportant aspect of the alignment between devices 701 and 801 is theparallelism of the planes of the respective substrates 300 of devices701 and 801 about the axes of the waveguides of respective opticaldevices 302 (FIG. 9B).

[0134] As seen in FIG. 9C, a lens module 808, preferably comprising alens 809 fixedly mounted onto a mounting substrate 810, is brought intoproximity with substrate 300 of device 801 and active integrated opticswaveguide device 302 of device 801, as by a vacuum engagement assembly811, connected to a suitable positioner (not shown), such as MellesGriot Nanoblock.

[0135] Also seen in FIG. 9C, the lens module 808 is precisely positionedwith respect to the active integrated optics waveguide device 302 ofdevice 801 with six degrees of freedom so as to achieve a high degree ofaccuracy in order to realize optimal optical coupling efficiency betweenthe fibers of fiber bundle 702 and the waveguides in device 302 ofdevice 801. This degree of accuracy is greater than that required in thepreviously described alignment steps illustrated in FIGS. 1A-1I andpreferably reaches one tenth of a micron.

[0136] Precise mounting of the lens module 808 with respect to theactive integrated optics waveguide device 302 of device 801 as describedhereinabove with respect to device 701 ensures that the images of thecenters of the ends of fibers of fiber bundle 702 lie in the same planeas the centers of the waveguides of waveguide device 302 of device 801.This precise mounting is preferably achieved by using the positioner(not shown) to manipulate the lens module 808 relative to substrate 300of device 801 such that the mode of each optical fiber in bundle 702matches the mode of at least one corresponding waveguide of waveguidedevice 302 of device 801 with relatively low light loss.

[0137] As seen in FIG. 9D, the lens module 808 is mounted in a desiredrelative position on the substrate 300 of device 801 inpendently of thepositioner by employing side mounting blocks 812 to fix the module 808in position on substrate 300 of device 801 upon precise mutual alignmentof the module 808 and the waveguide device 302 of device 801.

[0138] Preferably side mounting blocks 812 are carefully positionedalongside module 808 and are bonded thereto and to subtrate 300 ofdevice 801, preferably using a thin layer of UV curable adhesive 813which does not involve significant shrinkage during curing, as by use ofa UV light source 820.

[0139] It will be appreciated by persons skilled in the art the presentinvention is not limited by the claims which follow, rather the scope ofthe invention includes both combinations and subcombinations of thevarious features described hereinabove as well as variations andmodifications thereof which would occur to a person of ordinary skill inthe art upon reading the foregoing description and which are not inprior art.

1. An optical device comprising: at least one first substrate defining amultiplicity of optical fiber positioning grooves; a multiplicity ofoptical fibers fixed in each of said multiplicity of optical fiberpositioning grooves on said at least one first substrate, whereby saidmultiplicity of optical fibers lie in an optical fiber plane and theends of each of said multiplicity of optical fibers lie substantially ina first predetermined arrangement in said optical fiber plane; a secondsubstrate fixed onto said at least one first substrate such that an edgeof said second substrate extends beyond said ends of each of saidmultiplicity of optical fibers; a lens assembly comprising: a thirdsubstrate; and a lens fixed onto said third substrate, said lensassembly being mounted onto said second substrate such that the lenslies in a second predetermined arrangement with respect to said ends ofeach of said multiplicity of optical fibers, whereby the separationbetween said lens and said ends of each of said multiplicity of opticalfibers is defined in a plane perpendicular to said optical fiber planeto a first degree of accuracy and the separation between said lens andsaid ends of each of said multiplicity of optical fibers is defined insaid optical fiber plane to a second degree of accuracy, less than saidfirst degree of accuracy.
 2. An optical device according to claim 1 andwherein said at least one first substrate comprises a pair of firstsubstrates having said optical fiber positioning grooves thereonarranged in mutually facing relationship.
 3. An optical device accordingto claim 1 and wherein said lens comprises a cylindrical lens whichextends along a cylindrical lens axis.
 4. An optical device according toclaim 3 and wherein said cylindrical lens axis lies parallel to saidoptical fiber plane.
 5. An optical device according to claim 1 andwherein said third substrate is fixed in engagement with said edge ofsaid second substrate by an adhesive.
 6. An optical device according toclaim 4 and wherein said third substrate is fixed in engagement withsaid edge of said second substrate by an adhesive.
 7. An optical deviceaccording to claim 1 and wherein said multiplicity of optical fiberpositioning grooves are mutually parallel.
 8. An optical deviceaccording to claim 1 and wherein said multiplicity of optical fiberpositioning grooves are arranged in a fan arrangement in order tocompensate for optical aberrations.
 9. A method for producing an opticaldevice comprising the steps of: forming a multiplicity of optical fiberpositioning grooves on at least one first substrate; placing each of amultiplicity of optical fibers in each of said multiplicity of opticalfiber positioning grooves on said at least one first substrate;retaining each of said multiplicity of optical fibers in each of saidmultiplicity of optical fiber positioning grooves on said at least onefirst substrate, such that said multiplicity of optical fibers lie in anoptical fiber plane; precisely defining the ends of each of saidmultiplicity of optical fibers so that they all lie substantially in afirst predetermined arrangement; fixing a second substrate onto.said atleast one first substrate such that an edge of said second substrateextends beyond said ends of each of said multiplicity of optical fibers;fixing a lens onto a third substrate; precisely aligning said thirdsubstrate in engagement with said edge of said second substrate suchthat said lens lies in a second predetermined arrangement with respectto said ends of each of said multiplicity of optical fibers; and fixingsaid third substrate in engagement with said edge of said secondsubstrate such that said lens lies in a second predetermined arrangementwith respect to said ends of each of said multiplicity of opticalfibers, whereby the separation between said lens and said ends of eachof said multiplicity of optical fibers is defined in a planeperpendicular to said optical fiber plane to a first degree of accuracyand the separation between said lens and said ends of each of saidmultiplicity of optical fibers is defined in said optical fiber plane toa second degree of accuracy, less than said first degree of accuracy.10. A method according to claim 9 and wherein said at least one firstsubstrate comprises a pair of first substrates having said optical fiberpositioning grooves thereon arranged in mutually facing relationship.11. A method according to claim 9 and wherein said lens comprises acylindrical lens which extends along a cylindrical lens axis.
 12. Amethod according to claim 11 and wherein said precisely aligning stepand said fixing step arrange said cylindrical lens such that saidcylindrical lens axis lies parallel to said optical fiber plane.
 13. Amethod according to claim 9 and wherein said step of fixing said thirdsubstrate in engagement with said edge employs an adhesive.
 14. A methodaccording to claim 12 and wherein said step of fixing said thirdsubstrate in engagement with said edge employs an adhesive.
 15. A methodaccording to claim 9 and wherein said multiplicity of optical fiberpositioning grooves are mutually parallel.
 16. A method according toclaim 9 and wherein said multiplicity of optical fiber positioninggrooves are arranged in a fan arrangement in order to compensate foroptical aberrations.
 17. A method according to claim 9 and wherein saidstep of precisely aligning said third substrate in engagement with saidedge of said second substrate employs an external positioner.
 18. Anoptical device comprising: at least one optical substrate having formedthereon at least one waveguide; at least one base substrate onto whichsaid at least one optical substrate is fixed; and at least one opticalmodule, precisely positioned onto each at least one base substrate andfixed thereto by means of side mounting blocks thereby to preserveprecise mutual alignment of said at least one module and said at leastone waveguide.
 19. An optical device according to claim 18 and whereinsaid at least one optical module comprises a lens.
 20. An optical deviceaccording to claim 18 and wherein said at least one optical modulecomprises a cylindrical lens.
 21. An optical device according to claim18 and wherein said at least one optical module comprises at least oneoptical fiber.
 22. An optical device according to claim 21 and whereinsaid at least one optical module also comprises a lens which isoperative to couple light from said at least one fiber to said at leastone waveguide.
 23. An optical device according to claim 22 and whereinsaid lens is operative to couple light from a first number of fibers toa greater number of waveguides.
 24. An optical device according to claim22 and wherein said lens is operative to couple light from a firstnumber of fibers to an identical number of waveguides.
 25. An opticaldevice according to claim 23 and wherein said first number of waveguidescomprises at least one waveguide.
 26. An optical device according toclaim 24 and wherein said first number of waveguides comprises at leastone waveguide.
 27. An optical device according to claim 22 and whereinsaid at least one optical substrate is a light deflector.
 28. An opticaldevice according to claim 22 and also comprising output optics receivinglight from said at least one waveguide and including at least one outputfiber.
 29. An optical device according to claim 28 and wherein saidoutput optics includes at least one lens fixed onto said base substrateby means of side mounting blocks thereby to preserve precise mutualalignment of said at least one lens and said at least one waveguide. 30.An optical device according to claim 29 and wherein said at least oneoptical substrate is a light deflector.
 31. An optical device accordingto claim 30 and wherein said at least one optical substrate is formed ofgallium arsenide.
 32. An optical device according to claim 28 andwherein said at least one waveguide comprises a multiplicity ofwaveguides and wherein said output optics includes at least one lensreceiving light from multiple ones of said multiplicity of waveguides.33. An optical device according to claim 28 and wherein said at leastone waveguide comprises a multiplicity of waveguides formed on aplurality of optical substrates and wherein said output optics includesat least one lens receiving light from waveguides formed on multipleones of said plurality of optical substrates.
 34. An optical deviceaccording to claim 33 and wherein said at least one optical substrate isa light deflector.
 35. An optical device according to claim 34 andwherein said output optics includes at least one lens fixed onto saidbase substrate by means of side mounting blocks thereby to preserveprecise mutual alignment of said at least one lens and said at least onewaveguide.
 36. An optical device according to claim 35 and wherein saidat least one optical substrate is formed of gallium arsenide.
 37. Anoptical device according to claim 18 and wherein said optical modulecomprises: at least one first substrate defining a multiplicity ofoptical fiber positioning grooves; a multiplicity of optical fibersfixed in each of said multiplicity of optical fiber positioning grooveson said at least one first substrate, whereby said multiplicity ofoptical fibers lie in an optical fiber plane and the ends of each ofsaid multiplicity of optical fibers lie substantially in a firstpredetermined arrangement in said optical fiber plane; a secondsubstrate fixed onto said at least one first substrate such that an edgeof said second substrate extends beyond said ends of each of saidmultiplicity of optical fibers; a lens assembly comprising: a thirdsubstrate; and a lens fixed onto said third substrate, said lensassembly being mounted onto said second substrate such that the lenslies in a second predetermined arrangement with respect to said ends ofeach of said multiplicity of optical fibers, whereby the separationbetween said lens and said ends of each of said multiplicity of opticalfibers is defined in a plane perpendicular to said optical fiber planeto a first degree of accuracy and the separation between said lens andsaid ends of each of said multiplicity of optical fibers is defined insaid optical fiber plane to a second degree of accuracy, less than saidfirst degree of accuracy.
 38. An optical device according to claim 37and wherein said lens comprises a cylindrical lens.
 39. An opticaldevice according to claim 38 and wherein said at least one opticalsubstrate is a light deflector.
 40. An optical device according to claim38 and also comprising output optics receiving light from said at leastone waveguide and including at least one output fiber.
 41. An opticaldevice according to claim 40 and wherein said output optics includes atleast one lens fixed onto said base substrate by means of side mountingblocks thereby to preserve precise mutual alignment of said at least onelens and said at least one waveguide.
 42. An optical device according toclaim 41 and wherein said at least one optical substrate is a lightdeflector.
 43. An optical device according to claim 42 and wherein saidat least one optical substrate is formed of gallium arsenide.
 44. Anoptical device according to claim 40 and wherein said at least onewaveguide comprises a multiplicity of waveguides and wherein said outputoptics includes at least one lens receiving light from multiple ones ofsaid multiplicity of waveguides.
 45. An optical device according toclaim 40 and wherein said at least one waveguide comprises amultiplicity of waveguides formed on a plurality of optical substratesand wherein said output optics includes at least one lens receivinglight from waveguides formed on multiple ones of said plurality ofoptical substrates.
 46. An optical device according to claim 45 andwherein said at least one optical substrate is a light deflector.
 47. Anoptical device according to claim 46 and wherein said output opticsincludes at least one lens fixed onto said base substrate by means ofside mounting blocks thereby to preserve precise mutual alignment ofsaid at least one lens and said at least one waveguide.
 48. An opticaldevice according to claim 47 and wherein said at least one opticalsubstrate is formed of gallium arsenide.
 49. An optical devicecomprising: at least one optical substrate having formed thereon atleast one waveguide having a center which lies in a waveguide plane; abase substrate onto which said at least one optical substrate is fixedand defining at least one optical fiber positioning groove; and at leastone optical fiber fixed. in said at least one optical fiber positioninggroove on said base substrate, whereby a center of said at least oneoptical fiber lies in a plane which is substantially coplanar with saidwaveguide plane.
 50. An optical device according to claim 49 and alsocomprising electrical connections mounted on said base substrate.
 51. Anoptical device according to claim 49 and also comprising at least oneoptical module, precisely positioned onto said base substrate and fixedthereto by means of side mounting blocks thereby to preserve precisemutual alignment of said at least one module and said at least onewaveguide.
 52. An optical device according to claim 51 and wherein saidat least one optical substrate is a light deflector.
 53. An opticaldevice according to claim 52 and also comprising electrical connectionsmounted on said base substrate.
 54. A method for producing an opticaldevice comprising the steps of: forming at least one waveguide onto atleast one optical substrate; mounting said at least one opticalsubstrate onto at least one base substrate; and precisely positioning atleast one optical module onto said base substrate, including employingside mounting blocks thereby to preserve precise mutual alignment ofsaid at least one module and said at least one waveguide.
 55. A methodaccording to claim 54 and wherein said at least one optical modulecomprises a lens.
 56. A method according to claim 54 and wherein said atleast one optical module comprises a cylindrical lens.
 57. A methodaccording to claim 54 and wherein said at least one optical modulecomprises at least one optical fiber.
 58. A method according to claim 57and wherein said at least one optical module also comprises a lens whichis operative to couple light from said at least one fiber to said atleast one waveguide.
 59. A method according to claim 58 and wherein saidlens is operative to couple light from a first number of fibers to agreater number of waveguides.
 60. A method according to claim 58 andwherein said lens is operative to couple light from a first number offibers to an identical number of waveguides.
 61. A method according toclaim 59 and wherein said first number of waveguides comprises at leastone waveguide.
 62. A method according to claim 60 and wherein said firstnumber of waveguides comprises at least one waveguide.
 63. A methodaccording to claim 58 and wherein said at least one optical substrate isa light deflector.
 64. A method according to claim 58 and alsocomprising providing output optics receiving light from said at leastone waveguide and including at least one output fiber.
 65. A methodaccording to claim 64 and wherein said output optics includes at leastone lens fixed onto said base substrate by means of side mounting blocksthereby to preserve precise mutual alignment of said at least one lensand said at least one waveguide.
 66. A method according to claim 65 andwherein said at least one optical substrate is a light deflector.
 67. Amethod according to claim 66 and wherein said at least one opticalsubstrate is formed of gallium arsenide.
 68. A method according to claim64 and wherein said at least one waveguide comprises a multiplicity ofwaveguides and wherein said output optics includes at least one lensreceiving light from multiple ones of said multiplicity of waveguides.69. A method according to claim 64 and wherein said at least onewaveguide comprises a multiplicity of waveguides formed on a pluralityof optical substrates and wherein said output optics includes at leastone lens receiving light from waveguides formed on multiple ones of saidplurality of optical substrates.
 70. A method according to claim 69 andwherein said at least one optical substrate is a light deflector.
 71. Amethod according to claim 70 and wherein said output optics includes atleast one lens fixed onto said base substrate by means of side mountingblocks thereby to preserve precise mutual alignment of said at least onelens and said at least one waveguide.
 72. A method according to claim 71and wherein said at least one optical substrate is formed of galliumarsenide.
 73. A method according to claim 54 and wherein said opticalmodule comprises: at least one first substrate defining a multiplicityof optical fiber positioning grooves; a multiplicity of optical fibersfixed in each of said multiplicity of optical fiber positioning grooveson said at least one first substrate, whereby said multiplicity ofoptical fibers lie in an optical fiber plane and the ends of each ofsaid multiplicity of optical fibers lie substantially in a firstpredetermined arrangement in said optical fiber plane; a secondsubstrate fixed onto said at least one first substrate such that an edgeof said second substrate extends beyond said ends of each of saidmultiplicity of optical fibers; a lens assembly comprising: a thirdsubstrate; and a lens fixed onto said third substrate, said lensassembly being mounted onto said second substrate such that the lenslies in a second predetermined arrangement with respect to said ends ofeach of said multiplicity of optical fibers, whereby the separationbetween said lens and said ends of each of said multiplicity of opticalfibers is defined in a plane perpendicular to said optical fiber planeto a first degree of accuracy and the separation between said lens andsaid ends of each of said multiplicity of optical fibers is defined insaid optical fiber plane to a second degree of accuracy, less than saidfirst degree of accuracy.
 74. A method according to claim 73 and whereinsaid lens comprises a cylindrical lens.
 75. A method according to claim74 and wherein said at least one optical substrate is a light deflector.76. A method according to claim 74 and also comprising providing outputoptics receiving light from said at least one waveguide and including atleast one output fiber.
 77. A method according to claim 76 and whereinsaid output optics includes at least one lens fixed onto said basesubstrate by means of side mounting blocks thereby to preserve precisemutual alignment of said at least one lens and said at least onewaveguide.
 78. A method according to claim 77 and wherein said at leastone optical substrate is a light deflector.
 79. A method according toclaim 78 and wherein said at least one optical substrate is formed ofgallium arsenide.
 80. A method according to claim 76 and wherein said atleast one waveguide comprises a multiplicity of waveguides and whereinsaid output optics includes at least one lens receiving light frommultiple ones of said multiplicity of waveguides.
 81. A method accordingto claim 76 and wherein said at least one waveguide comprises amultiplicity of waveguides formed on a plurality of optical substratesand wherein said output optics includes at least one lens receivinglight from waveguides formed on multiple ones of said plurality ofoptical substrates.
 82. A method according to claim 81 and wherein saidat least one optical substrate is a light deflector.
 83. A methodaccording to claim 81 and wherein said output optics includes at leastone lens fixed onto said base substrate by means of side mounting blocksthereby to preserve precise mutual alignment of said at least one lensand said at least one waveguide.
 84. A method according to claim 83 andwherein said at least one optical substrate is formed of galliumarsenide.
 85. A method comprising: forming on at least one opticalsubstrate at least one waveguide having a center which lies in awaveguide plane; fixing said at least one optical substrate onto a basesubstrate and defining on said base substrate at least one optical fiberpositioning groove; and fixing at least one optical fiber in said atleast one optical fiber positioning groove on said base substrate,whereby a center of said at least one optical fiber lies in a planewhich is substantially coplanar with said waveguide plane.
 86. A methodaccording to claim 85 and also comprising electrical connections mountedon said base substrate.
 87. A method according to claim 85 and alsocomprising providing at least one optical module, precisely positionedonto said base substrate and fixed thereto by means of side mountingblocks thereby to preserve precise mutual alignment of said at least onemodule and said at least one waveguide.
 88. A method according to claim87 and wherein said at least one optical substrate is a light deflector.89. A method according to claim 88 and also comprising mountingelectrical connections on said base substrate.
 90. A method forproducing an optical device comprising the steps of: lithographicallyforming a multiplicity of waveguides onto an optical substrate; mountingsaid optical substrate onto a base substrate; and precisely positioninga fiber optic module, having a multiplicity of optical fiber ends and anoptical mode modifying lens, onto said base substrate, including: usingat least one external positioner, manipulating at least one of the fiberoptic module and the base substrate relative to the other such that themode of each optical fiber matches the mode of at least onecorresponding waveguide with relatively low light loss; and fixing thefiber optic module in a desired relative position on said base substrateindependently of said external positioner; and disengaging the at leastone external positioner from the modulated light source.
 91. A methodaccording to claim 90 and wherein the step of fixing comprises employingside mounting blocks to fix said module in position on said basesubstrate upon precise mutual alignment of said module and saidmultiplicity of waveguides.
 92. A method according to claim 90 and alsocomprising the step of producing a fiber optic module including thesteps of: forming a multiplicity of optical fiber positioning grooves onat least one first substrate; placing each of a multiplicity of opticalfibers in each of said multiplicity of optical fiber positioning grooveson said at least one first substrate; retaining each of saidmultiplicity of optical fibers in each of said multiplicity of opticalfiber positioning grooves on said at least one first substrate, suchthat said multiplicity of optical fibers lie in an optical fiber plane;precisely defining the ends of each of said multiplicity of opticalfibers so that they all lie substantially in a first predeterminedarrangement; fixing a second substrate onto said first substrate suchthat an edge of said second substrate extends beyond said ends of eachof said multiplicity of optical fibers; fixing a lens onto a thirdsubstrate; precisely aligning said third substrate in engagement withsaid edge of said second substrate such that said lens lies in a secondpredetermined arrangement with respect to said ends of each of saidmultiplicity of optical fibers; and fixing said third substrate inengagement with said edge of said second substrate such that said lenslies in a second predetermined arrangement with respect to said ends ofeach of said multiplicity of optical fibers, whereby the separationbetween said lens and said ends of each of said multiplicity of opticalfibers is defined in a plane perpendicular to said optical fiber planeto a first degree of accuracy and the separation between said lens andsaid ends of each of said multiplicity of optical fibers is defined insaid optical fiber plane to a second degree of accuracy, less than saidfirst degree of accuracy.
 93. A method according to claim 91 and alsocomprising the step of producing a fiber optic module including thesteps of: forming a multiplicity of optical fiber positioning grooves onat least one first substrate; placing each of a multiplicity of opticalfibers in each of said multiplicity of optical fiber positioning grooveson said at least one first substrate; retaining each of saidmultiplicity of optical fibers in each of said multiplicity of opticalfiber positioning grooves on said at least one first substrate, suchthat said multiplicity of optical fibers lie in an optical fiber plane;precisely defining the ends of each of said multiplicity of opticalfibers so that they all lie substantially in a first predeterminedarrangement; fixing a second substrate onto said first substrate suchthat an edge of said second substrate extends beyond said ends of eachof said multiplicity of optical fibers; fixing a lens onto a thirdsubstrate; precisely aligning said third substrate in engagement withsaid edge of said second substrate such that said lens lies in a secondpredetermined arrangement with respect to said ends of each of saidmultiplicity of optical fibers; and fixing said third substrate inengagement with said edge of said second substrate such that said lenslies in a second predetermined arrangement with respect to said ends ofeach of said multiplicity of optical fibers, whereby the separationbetween said lens and said ends of each of said multiplicity of opticalfibers is defined in a plane perpendicular to said optical fiber planeto a first degree of accuracy and the separation between said lens andsaid ends of each of said multiplicity of optical fibers is defined insaid optical fiber plane to a second degree of accuracy, less than saidfirst degree of accuracy.
 94. A method according to claim 93 and whereinsaid optical substrate is gallium arsenide.
 95. A method according toclaim 94 and wherein said optical device functions as a switch.
 96. Amethod according to claim 58 and also comprising the step of positioningoutput optics including at least one output fiber on said at least onebase substrate so as to receive light from said at least one waveguide.97. A method according to claim 96 and wherein said step of positioningoutput optics includes employing side mounting blocks thereby topreserve precise mutual alignment of said at least one lens and said atleast one waveguide.
 98. A method according to claim 96 and wherein saidat least one waveguide comprises a multiplicity of waveguides andwherein the step of positioning said output optics includes positioningat least one lens so as to receive light from multiple ones of saidmultiplicity of waveguides.
 99. A method according to claim 64 andwherein said at least one waveguide comprises stacking a plurality ofbase substrates each having mounted thereon at least one opticalsubstrate having formed thereon at least one waveguide and wherein saidstep of positioning said output optics includes arranging at least onelens to receive light from waveguides formed on multiple ones of saidplurality of optical substrates.
 100. A method according to claim 99 andwherein said step of positioning said output optics includes employingside mounting blocks thereby to preserve precise mutual alignment ofsaid at least one lens and said at least one waveguide.